Systems and methods for creating a honeycomb core with venting pathways

ABSTRACT

A method for creating a honeycomb core having venting pathways includes controlling where a resin is applied to sheets to form the venting pathways. A honeycomb substrate is then formed from the sheets.

INTRODUCTION

The present disclosure relates to systems and methods for creatingcores. More specifically, the present disclosure relates to systems andmethods for creating cores having venting pathways.

BACKGROUND

Decorative or interior panels and acoustic panels made from a compositepart are used in many industries. The composite part includes ahoneycomb core with one or more surface plies or laminates applied tothe honeycomb core. The honeycomb core separates the surface plies byspacing the surface plies apart and adding thickness to the panel, thusincreasing bending strength of the panel. However, during manufacturingof the composite part, especially in Out of Autoclave (OOA) productionsystems, volatiles are generated and may be sealed inside the compositepart since the walls of the honeycomb core may not be permeable orporous enough to allow the volatiles to escape. During the lifetime ofthe composite part outgassing volatiles may result in quality issuessuch as bubbling on the decorative surface or delamination.

Various solutions have been provided to address the issue of unventedvolatiles in honeycomb cores. These solutions include increasing theprocessing time to create the composite part in order to allow degassingand adding additional processing steps to score the composite part.However, these solutions may increase the cost of manufacturing.

Thus, there is a need in the art for systems and methods for creatingcomposite parts with cores that permit low cost venting and degassingpathways.

SUMMARY

According to one aspect, a method for creating a honeycomb core havingventing pathways is provided. The method includes controlling where aresin is applied to sheets to form the venting pathways. A honeycombsubstrate is then formed from the sheets.

According to another aspect, a honeycomb core is provided. The honeycombcore includes a honeycomb substrate having a number of open cells, aresin skin disposed overtop the honeycomb substrate, and ventingpathways disposed in the resin skin that communicate between the opencells.

According to yet another aspect, a section is provided. The sectionincludes a number of sheets stacked one upon another to form thesection. Each of the sheets includes a resin affinity portion and aresin repellant portion.

The features, functions, and advantages that have been discussed may beachieved independently in various aspects or may be combined in otheraspects further details of which can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1 is a schematic diagram of a system for creating a honeycomb corewith venting pathways, according to an exemplary aspect;

FIG. 1A is an isometric view of a sheet having perforated holes used inthe system of FIG. 1, according to an exemplary aspect;

FIG. 2A is a schematic diagram of a printing array used in the system ofFIG. 1, according to an exemplary aspect;

FIG. 2B is a schematic diagram of a rotary coating machine used in thesystem of FIG. 1, according to an exemplary aspect;

FIG. 3 is a schematic diagram of a mesh screen for coating used in thesystem of FIG. 1, according to an exemplary aspect;

FIG. 4 is an enlarged isometric view of a honeycomb substrate, accordingto an exemplary aspect;

FIG. 5 is cross-section view of a portion of the honeycomb substrateviewed in the direction of arrows 5-5 in FIG. 4, according to anexemplary aspect;

FIG. 6 is an exemplary process flow diagram illustrating a method ofcreating a honeycomb core having venting pathways using the system ofFIG. 1, according to an exemplary aspect;

FIG. 7 is a schematic diagram of another system for creating a honeycombcore with venting pathways, according to an exemplary aspect;

FIG. 8 is an exemplary process flow diagram illustrating a method ofcreating a honeycomb core having venting pathways using the system ofFIG. 7, according to an exemplary aspect;

FIG. 9 is a flow diagram of aircraft production and service methodology;and

FIG. 10 is a block diagram of an aircraft.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses.

Referring to FIG. 1, a schematic diagram of a system 10 formanufacturing a honeycomb core with venting pathways is shown. Thesystem 10 may be employed in the context of aircraft manufacturing andservice, as will be described below. For example, the system 10 may beused in component and subassembly manufacturing of an aircraft includinginterior fabrication, acoustic panels, system integration of theaircraft, airframe fabrication, and routine maintenance and service ofthe aircraft. However, the system 10 may be used in various otherindustries, including automotive, construction, graphics, and generaltransportation industry, to name but a few.

The system 10 includes a sheet 12 that is fed into a first machine 14.The sheet 12 may be roll fed using a roll of material fed in acontinuous process (not shown) into the first machine 14 or sheet fed,as illustrated in FIG. 1. The sheet 12 is preferably an aromaticpolyamide paper, such as sold under the trademark NOMEX®, that providesmechanical toughness, flexibility and resilience. However, the sheet 12may be a woven fabric, cellulose paper, plastic, or aluminum withoutdeparting from the scope of the present disclosure. The sheet 12 iscomprised of a resin repellant material or a resin affinity material. Aresin repellant material is a material that prevents a resin, such asphenolic resin, from adhering to the sheet 12. A resin affinity materialis a material that allows a resin, such as phenolic resin, to adhere tothe sheet 12. The sheet 12 may be porous or non-porous to ventinggasses. A sheet 12 which is porous is defined as having an intrinsicpermeability of at least 1×10⁻¹³ m². A sheet 12 which is non-porous isdefined as having an intrinsic permeability of less than 1×10⁻¹³ m². Inthe example provided, the sheet 12 is comprised of an aromatic polyamidepaper and is thus a resin affinity material and porous. In one aspect,the sheet 12 may be coated with a material that is a resin affinitymaterial or a resin repellant material. In another aspect, the sheet 12includes a plurality of holes 15, shown in FIG. 1A, that receive theresin repellant material, as will be described below.

The first machine 14 is configured to apply a first phase of treatmentonto the sheet 12. The first phase of treatment includes applying one ofa resin repellant or a resin affinity material 16 onto the sheet 12 tocreate a resin affinity portion 12A and a resin repellant portion 12B.In the example where the sheet 12 is a resin affinity material, thefirst machine 14 applies a resin repellant onto the sheet 12. Thus,exposed areas of the sheet 12 form the resin affinity portion 12A whileareas covered by the resin repellant form the resin repellant portion12B. Where the sheet 12 is a resin repellant material, the first machine14 applies a resin affinity material onto the sheet 12. Thus, exposedareas of the sheet 12 form the resin repellant portion 12B while areascovered by the resin affinity material form the resin affinity portion12A. The resin repellant or resin affinity material 16 is applied in aregular pattern onto a surface 18 of the sheet 12. In another aspect,the resin repellant or resin affinity material 16 may be applied in anirregular pattern (not shown). The shape and pattern of the resinrepellant or resin affinity material 16 may vary without departing fromthe scope of the present disclosure. In the example provided, the resinrepellant or resin affinity material 16 is disposed on the surface 18 asdiscrete dots 16A arranged in parallel rows 16B to provide regularventing pathways (not shown in FIG. 1) for each of a column of honeycombstructures, as will be described below. Where the sheet 12 includesholes 15 (FIG. 1A), the resin repellant or resin affinity material 16 isapplied into the holes 15 in order to assure that the holes 15ultimately remain open for venting. In one aspect, the resin repellantor resin affinity material 16 is applied to one side of the sheet 12. Inanother aspect, the resin repellant or resin affinity material 16 isapplied to both sides of the sheet 12 to increase the communicationbetween venting pathways. Examples of resin repellant materials includematerials having a surface energy lower than the resin that is to berepelled. One example includes low surface energy wax-based materialssuch as inkjet printable UV Masking Black Wax 130 Degree Wax-JCHP7941made by Luscher. Examples of resin affinity materials include anysubstrate material that has been treated to allow bonding of the resinto the substrate. For example, plasma, corona, or flame treatment of thesurface 18 of the sheet 12 creates the resin affinity materialsufficient to allow bonding by the resin.

The first machine 14 may apply the first phase of treatment onto thesheet 12 in various ways, including printing and coating. Turningbriefly to FIG. 2A, a schematic diagram of a printing machine 19 isillustrated for use as the first machine 14. The printing machine 19 mayperform at least one of digital printing, screen printing, lithographyprinting, flexography printing, and offset printing. The printingmachine 19 generally includes a printer array 19A having a plurality ofprinting nozzles 19B. Each of the printing nozzles 19B is configured toapply or print one or a combination of the resin repellant or resinaffinity material 16 directly onto the sheet 12 following apreprogrammed pattern. In one aspect, the sheet 12 is moved, for examplelongitudinally and/or laterally relative to the printer array 19A. Inanother aspect, the printer array 19A is moved, for example for examplelongitudinally and/or laterally relative to the sheet 12. The printerarray 19A may apply more than one type of material to the sheet 12, forexample adhesives and wax. In one aspect of the present disclosure, theprinter array 19A prints a desiccant, an e-ink, an antimicrobialmaterial, a fire-retardant material, an activated charcoal, and/or anintumescent material onto the sheet 12. Thus, some of the printingnozzles 19B may print one type of material and others of the printingnozzles 19B may print another type of material. In another aspect, theprinting machine 19 may be used in series with another printing machine(not shown). In this aspect, the printing machine 19 applies one of theresin repellant or resin affinity material 16 and the other printingmachine (not shown) applies the other of the resin repellant or resinaffinity material 16.

In another aspect, the resin repellant or resin affinity material 16 iscoated onto the sheet 12. The coating includes at least one of coatingwith and a rotary screen coating or a mesh screen coating. Turningbriefly to FIG. 2B, a schematic diagram of a rotary screen coatingmachine 20 is illustrated for use as the first machine 14. The rotaryscreen coating machine 20 includes rollers 22 that feed the sheet 12past a drum 24. The drum 24 is filled with the resin repellant or resinaffinity material 16 to be applied to the sheet 12. In one aspect, thedrum 24 may be divided (not shown) to apply both the resin repellantmaterial and resin affinity material 16 onto the sheet 12. In anotheraspect, multiple drums 24 (not shown) may be used in series to applyboth the resin repellant material and resin affinity material 16 ontothe sheet 12. It should be appreciated that the rotary screen coatingmachine 20 may include additional rollers, including a roller (notshown) disposed opposite the drum 24 to compress the sheet 12therebetween. The drum 24 includes apertures 26 disposed through asurface 28 of the drum 30. A squeegee or brush 31 applies the resinrepellant or resin affinity material 16 through the apertures 26 ontothe sheet 12. Thus, the size, shape, and spacing of the apertures 26correspond to a desired pattern of the resin repellant or resin affinitymaterial 16 applied to the sheet 12. In one aspect of the presentdisclosure, a desiccant, an e-ink, an antimicrobial material, afire-retardant material, an activated charcoal, and/or an intumescentmaterial is coated onto the sheet 12 using the coating machine 20. FIG.3 illustrates a screen mesh 32 used in mesh screen coating. The screenmesh 32 includes holes 34 disposed therethrough. The screen mesh 32 isdisposed over the sheet 12. The resin repellant or resin affinitymaterial 16 is coated onto the sheet 12 through the screen mesh 32 tocreate a desired pattern. In one aspect, both the resin repellant andresin affinity material 16 is applied through the screen mesh 32.

Returning to FIG. 1, once the resin affinity portion 12A and the resinrepellant portion 12B have been created on the sheet 12, the sheet 12 isfed into a second machine 36. The second machine 36 is configured toapply a second phase of treatment onto the sheet 12. In one aspect, theapplied resin affinity portion 12A and the resin repellant portion 12Bare dried before the second phase of treatment begins. The second phaseof treatment includes applying an adhesive 38 onto the surface 18 of thesheet 12. The adhesive 38 is applied to the resin affinity portion 12A.The adhesive 38 is applied as strips 38A onto the sheet 12. Subsequent,alternating sheets 12 have adhesive 38 applied in strips 38B that areoffset from the strips 38A in order to form a honeycomb-like structurewhen expanded. The adhesive 38 may be applied to the sheet 12 usingprinting or coating, as described above for the first machine 14. Inaddition, the first machine 14 and the second machine 36 may be switchedin the system 10 such that the second machine 36 applies the adhesive 38onto the sheets 12 before the creation of the resin affinity portion 12Aand the resin repellant portion 12B by the first machine 14.

A number of the sheets 12 are then stacked to form a block 40. As notedabove, the sheets 12 have alternating strips of adhesive 38. The strips38A of adhesives 38 and the strips 38B of adhesives 38 adhere the sheets12 together. The adhesives 38 may be allowed to cure before optionallyslicing or cutting the block 40 into sections 42. The sections 42 arethen placed into a third machine 44 for expanding the sections 42 toform a honeycomb substrate 46. The honeycomb substrate 46 includes anumber of open cells 47 arranged in a honeycomb-like configuration.

The honeycomb substrate 46 is then placed into a dip coating machine 48to apply a resin over the honeycomb substrate 46. The resin adheres tothe resin affinity portions 12A and does not adhere to the resinrepellant portions 12B. The resin is preferably a phenolic resin havinga surface energy ranging from 40 to 50 dyn/cm. The resin may alsoinclude Epoxy and polyester resins. The resin repellant portions 12B,where no resin is adhered to the honeycomb substrate 46, will formventing pathways, as will be described in greater detail below.

The honeycomb substrate 46 is then removed from the dip coating machine48 and placed in a curing machine 50. The curing machine 50, such as anautoclave, cures the resin on the honeycomb substrate 46 at an elevatedtemperature. Once cured, the honeycomb substrate 46 is placed in adegrading machine 52. The degrading machine 52 degrades the resinrepellant portion 12B to form a honeycomb core 60, shown in FIGS. 4 and5, having venting pathways 68 that allow outgassing of volatiles. In oneaspect, degrading the resin repellant portion 12B includes washing theresin repellant portion 12B in a solvent. In another aspect, degradingthe resin repellant portion 12B includes thermally degrading the resinrepellant portion 12B. Thermally degrading includes heating the resinrepellant portion 12B to degrade the material thereby increasing theporosity of the resin repellant portion 12B. In yet another aspect,degrading the resin repellant portion 12B includes gravity floating theresin repellant portion 12B. Gravity floating includes submerging thehoneycomb substrate 46 in a solution (not shown) that allows the resinrepellant portion 12B to float in the solution. In one aspect, degradingthe resin repellant portion 12B includes degrading the honeycombsubstrate 46 to make the honeycomb substrate 46 porous. Once complete,the honeycomb core 60 may be placed in one or more post-processingmachines 54 (FIG. 1), such as laminating machines, out-of-autoclavecuring machines, etc., to form a final part (not shown).

FIG. 4 illustrates an enlarged portion of the honeycomb core 60 producedby the system 10. FIG. 5 illustrates an enlarged cross-section of thehoneycomb core 60 viewed in the direction of arrows 5-5 in FIG. 4. Thehoneycomb core 60 includes the honeycomb substrate 46 and a resin skin62 disposed overtop the honeycomb substrate 46. The honeycomb substrate46 includes walls 64 arranged in a honeycomb-like pattern. Six walls 64are connected to form the open cell 47 in the honeycomb substrate 46.The resin skin 62 is disposed on the walls 64 in the resin affinityportions 12A but is not disposed overtop the walls 64 in the resinrepellant portions 12B (shown in FIG. 5). Thus, venting pathways 68 areformed in the resin skin 62. The venting pathways 68 communicate throughthe walls 64 to the open cell 47. Thus, the venting pathways 68 aredefined by inner venting openings 68A formed in the resin skin 62 on aninner side 64A of the walls 64 and outer venting openings 68B formed inthe resin skin 62 on an outer side 64B of the walls 64. The innerventing openings 68A and the outer venting openings 68B on the wall 64are aligned. Thus, the venting pathways 68 are discrete openings formedin the resin skin 62 that allow vapor communication, i.e. vaporpropagation, between adjacent ones of the open cells 47. Where thehoneycomb substrate 46 is porous, either by degrading or naturally, thevapor communication occurs through the honeycomb substrate 46. Where thehoneycomb substrate 46 is non-porous and holes 15 (FIG. 1A) have beenformed in the sheets 12 (FIG. 1A), the holes 15 form part of the ventingpathways. It should be appreciated that the number and location ofventing pathways 68 is controlled by the location of the resin repellantor resin affinity material 16 (FIG. 1) applied to the sheets 12.

With reference to FIG. 6, and continued reference to FIGS. 1-5, a flowchart of a method 100 for forming the honeycomb core 60 is illustrated.The method 100 begins at block 102 where the resin affinity portions 12Aand the resin repellant portions 12B are created on the sheets 12. Wherethe sheets 12 are porous, the resin repellant portions 12B are createdby applying a resin repellant material to the sheets 12 by the firstmachine 14. Where the sheets 12 are non-porous or resin repellant, theresin affinity portions 12A are created by applying a resin affinitymaterial to the sheets 12 by the first machine 14. Where the sheets haveholes 15 (FIG. 1A) perforated therethrough, the resin repellant portions12B are aligned with the holes 15. The resin affinity portions 12A orthe resin repellant portions 12B may be created by digital printing,screen printing, lithography printing, flexography printing, offsetprinting, mesh screen coating or rotary screen coating, as describedabove. The resin affinity portions 12A or the resin repellant portions12B are applied in a regular, repeating pattern to assure that each opencell 47 (FIG. 5) has a venting pathway 68 (FIG. 5) when cut intosections 42. The location of the resin affinity portion 12A and theresin repellant portion 12B is selected to optimize the performance ofthe honeycomb substrate 46. Optimizing performance may include selectingfor strength or other functions. For example, the pattern may help withenhancing strength (compression strength, shear strength etc.) of thehoneycomb substrate 46 relative to other functions. The designparameters include locations, shapes, and number of the venting pathways68, or the shape of the open cells 47.

Next, at block 104, the honeycomb substrate 46 is formed by applying theadhesive 38 to the sheets 12 and stacking the sheets 12 to form theblock 40. The adhesive 38 is applied in strips 38A and strips 38B thatare offset from one another on alternating sheets 12. The block 40 isthen expanded by the third machine 44 to form the honeycomb substrate46. It should be appreciated that the block 40 may be cut into sections42 before or after entering the third machine 44. The method thenproceeds to block 106.

At block 106 the resin is applied to the honeycomb substrate 46. Theresin will adhere to the resin affinity portions 12A and not adhere tothe resin repellant portions 12B. The resin is then cured to form thehoneycomb core 60.

At block 108 either the resin affinity portion 12A or the resinrepellant portion 12B is degraded by the degrading machine 52. Thedegrading machine 52 includes at least one of washing the resinrepellant portion 12B in a solvent, thermally degrading the resinrepellant portion 12B, or gravity floating the resin repellant portion12B. Degrading the resin repellant portion 12B forms the ventingpathways 68 in the honeycomb core 60. In one aspect, the curing machine50 and the degrading machine 52 are the same machine and heating duringcuring degrades the resin repellant portion 12B.

FIG. 7 is a schematic diagram of another system 200 for creating thehoneycomb core 60. The system 200 is similar to the system 10 and likecomponents are indicated by like reference numbers. However, in thesystem 200, the dip coating machine 48 is not included. Instead, a resinmaterial 70 is directly printed onto the sheet 12 by a resin printer 72.The resin material 70 is printed onto the sheet 12 to define openings 74where no resin material 70 is present. The openings 74 are applied in aregular pattern onto the surface 18 of the sheet 12. The shape andpattern of the resin material 70 may vary without departing from thescope of the present disclosure. In the example provided, the resinmaterial 70 is disposed on the surface 18 such that the openings 74 arediscrete dots arranged in parallel rows 76 to provide regular ventingpathways for each of the open cells 47 in the honeycomb substrate 46.Other arrangements, including non-parallel configurations (not shown)may be employed. The openings 74 are arranged to optimize theperformance of the honeycomb substrate 46. Optimizing performance mayinclude selecting for strength or other functions. For example, thearrangement of openings 74 may help with enhancing strength (compressionstrength, shear strength etc.) of the honeycomb substrate 46. The designparameters include locations, shapes, and number of the openings 74, orthe shape of the open cells 47. Where the sheet 12 includes holes 15(FIG. 1A), the resin material 70 is applied such that the openings 74align with the holes 15. In one aspect, the resin material 70 is appliedto one side of the sheet 12. In another aspect, the resin material 70 isapplied to both sides of the sheet 12 to increase the communicationbetween venting pathways by assuring that resin material 70 onalternating, stacked sheets 12 does not block the openings 74. Once theresin material 70 has been applied to the sheet 12, an adhesive printer78 applies the adhesive 38 onto the surface 18 of the sheet 12. Theadhesive 38 is applied as strips 38A onto the sheet 12. Subsequent,alternating sheets 12 have adhesive 38 applied in strips 38B that areoffset from the strips 38A in order to form the honeycomb substrate 46when expanded by the third machine 44.

With reference to FIG. 8, and continued reference to FIGS. 4, 5, and 7,a flow chart of a method 300 for creating the honeycomb core 60 usingthe system 200 is illustrated. The method 300 begins at block 302 byprinting the resin material 70 on selective areas of the sheets 12. Asnoted above, the resin material 70 is printed to define openings 74 onthe surface 18 of the sheet 12. In one aspect, the resin material 70 isprinted on one side of each of the sheets 12. In another aspect, theresin material 70 is printed on both sides of the sheets 12.

Next, at block 304, the adhesive 38 is printed on the sheets 12 by theadhesive printer 78. The adhesive 38 is printed in strips 38A and strips38B that are offset from one another on alternating sheets 12. At block306 the sheets 12 are stacked to form the block 40. The adhesive 38adheres the sheets 12 together. At block 308 the honeycomb core 60 isformed by expanding the block 40 using the third machine 44. At block310 the honeycomb core 60 is cured by the curing machine 50 and themethod 300 ends.

The honeycomb core 60 produced using the system 10 with method 100 andthe system 200 with the method 300 may be used in various compositeparts. The venting pathways 68 allow volatile gasses to escape thehoneycomb core 60 without damaging any laminates or surface sheets thatmay be applied during post processing.

Aspects of the system 10 and the system 200 described above, as well asthe method 100 and the method 300, may be employed in the context of anaircraft manufacturing and service method 500 as shown in FIG. 9 and anaircraft 502 as shown in FIG. 10. During pre-production, exemplarymethod 500 may include specification and design 504 of the aircraft 502and material procurement 506. During production, component andsubassembly manufacturing 508 and system integration 510 of the aircraft502 takes place. Thereafter, the aircraft 502 may go throughcertification and delivery 512 in order to be placed in service 514.While in service by a customer, the aircraft 502 is scheduled forroutine maintenance and service 516 (which may also includemodification, reconfiguration, refurbishment, and so on).

Each of the processes of the systems and methods described herein may beperformed or carried out by a system integrator, a third party, and/oran operator (e.g., a customer). For the purposes of this description, asystem integrator may include without limitation any number of aircraftmanufacturers and major-system subcontractors; a third party may includewithout limitation any number of venders, subcontractors, and suppliers;and an operator may be an airline, leasing company, military entity,service organization, and so on.

As shown in FIG. 10, the aircraft 502 produced by exemplary method 500may include an airframe 518 with a plurality of systems 520 and aninterior 522. Examples of systems 520 include one or more of apropulsion system 524, an electrical system 526, a hydraulic system 528,and an environmental system 530. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of thedisclosure may be applied to other industries, such as the automotiveindustry.

The system and methods described above may be employed during any one ormore of the stages of the exemplary method 500. For example, componentsor subassemblies corresponding to component and subassemblymanufacturing 508 may be fabricated or manufactured in a manner similarto components or subassemblies produced while the aircraft 502 is inservice. Also, one or more apparatus aspects, method aspects, or acombination thereof may be utilized during the component and subassemblymanufacturing 508 and system integration 510, for example, bysubstantially expediting assembly of or reducing the cost of an aircraft502. Similarly, one or more of apparatus aspects, method aspects, or acombination thereof may be utilized while the aircraft 502 is inservice, for example and without limitation, to maintenance and service516. Aspects of the system 10 and the system 200 described above, aswell as the methods 100 and 300, may be employed with the component andsubassembly manufacturing 508, the system integration 510, the routinemaintenance and service 516, the airframe 518, and the interior 522.

The description of the present disclosure is merely exemplary in natureand variations that do not depart from the gist of the presentdisclosure are intended to be within the scope of the presentdisclosure. Such variations are not to be regarded as a departure fromthe spirit and scope of the present disclosure.

The following is claimed:
 1. A method for creating a honeycomb corehaving venting pathways, the method comprising: printing a resin ontosheets to form locations with resin and locations with no resin, whereinthe sheets are non-porous to venting gas prior to printing the resin;printing an adhesive onto the sheets after the resin has been applied,wherein the adhesive is different than the resin; forming a honeycombsubstrate from the sheets; forming the honeycomb core from the honeycombsubstrate; and degrading the sheets to make the sheets porous at thelocations with no resin, wherein the venting pathways are defined by allthe locations with no resin that are degraded.
 2. The method of claim 1,wherein forming the honeycomb substrate includes stacking the sheets toform a block.
 3. The method of claim 2, wherein forming the honeycombcore from the honeycomb substrate includes expanding the block to formthe honeycomb core.
 4. The method of claim 1, further comprising curingthe resin.
 5. The method of claim 1, further comprising applying adesiccant to the sheets.
 6. The method of claim 1, further comprisingapplying at least one of an e-ink, an antimicrobial material, afire-retardant material, an activated charcoal, and an intumescentmaterial to the sheets.
 7. The method of claim 1, further comprisingstacking the sheets prior to forming the honeycomb substrate.
 8. Themethod of claim 1, further comprising stacking the sheets and adheringthe sheets together where the printed adhesive is located to form ablock.
 9. The method of claim 8, further comprising expanding the blockto form the honeycomb core.
 10. The method of claim 7, furthercomprising printing the resin only on one side of each of the sheets.11. The method of claim 7, further comprising printing the resin on eachside of each of the sheets.
 12. The method of claim 1, furthercomprising perforating the sheets to form holes.
 13. The method of claim1, wherein the sheets are comprised of one of a non-porous cellulosepaper, thermoplastic, Aluminum, and non-porous fabric.
 14. The method ofclaim 1, wherein printing the resin onto the sheets includes formingopenings in the resin to define the venting pathways.
 15. The method ofclaim 1, wherein the resin is applied by a resin printer.
 16. The methodof claim 15, wherein the adhesive is applied by an adhesive printerseparate from the resin printer.
 17. The method of claim 1, whereinprinting the resin includes at least one of digital printing, screenprinting, lithography printing, flexography printing, and offsetprinting.
 18. The method of claim 12, wherein the resin is printed onthe sheets to form openings that communicate with the holes in thesheets.
 19. A method for creating a honeycomb core having ventingpathways, the method comprising: printing a resin onto sheets to formlocations with resin and locations with no resin, wherein the sheets arenon-porous to venting gas prior to printing the resin; printing anadhesive onto the sheets after the resin has been applied, wherein theadhesive is different than the resin; forming a honeycomb substrate fromthe sheets by stacking the sheets to form a block; forming the honeycombcore from the honeycomb substrate by expanding the block; curing theresin; and degrading the sheets to make the sheets porous at thelocations with no resin, wherein the venting pathways are defined by allthe locations with no resin that are degraded.
 20. The method of claim19, further comprising applying a desiccant to the sheets.
 21. Themethod of claim 19, further comprising applying at least one of ane-ink, an antimicrobial material, a fire-retardant material, anactivated charcoal, and an intumescent material to the sheets.